Home

9-06-BZC 300 Controller Manual

1. FIGURE 35 ROBERTS GORDON BZC 300 Internal Components Diagram 8 1 COMPONENT LIST P N Description 11 NA RIBBON CABLE SOCKET 1 10000202 MAINS FUSE VOLTAGE 500mA 12 10032300 BZC EPROM 300 2 NA LED RELAY STATUS 13 10000400 BZC INPUT CHIP 16 PIN PC815 3 NA VOLTAGE SELECTOR SWITCH 14 10000702 CABLE ENTRY PLATE NOT SHOWN 4 NA TRANSFORMER 12V DC 15 10000703 CLIP COVER AND SCREW 5 10000208 LOW VOLTAGE FUSE BOARD 4 PACK NOT SHOWN 315mA 16 10000401 BZC INPUT CHIP 8 PIN PC815 6 10000203 LOW VOLTAGE FUSE SENSOR 315mA 7 NA LOW VOLTAGE LED INDICATION 8 10000300 BZC TIMEKEEPER M48T02 9 NA PROCESSOR CHIP 10 10000800 BZC COMMS CHIP A WARNING Use only genuine ROBERTS GORDON replacement parts Use of parts not specified by Roberts Gordon voids warranty Failure to follow these instructions can result in death injury or property damage 38 8 2 REPLACEMENT PARTS INSTRUCTIONS Electrical Shock Hazard Disconnect electrical power before servicing T Replace door before operating uy Failure to follow these instructions 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 can result in death or electrical shock 10000202 Mains Fuse 500mA 250V fuse protects the controller from power surges lightning and incorrect wiring If the mains fuse needs replacing the following steps must be taken Turn off the power to the controller Remove the clips and screws from the co
2. Pressure Switch P S Pressure Switch P S FIGURE 1 Example Site Layout Drawing SEcTION 1 INTRODUCTION 1 6 INTERNAL CONNECTION INFORMATION The following Section shows the configuration of relays and inputs for the example layout shown on Below is a diagram showing the terminal layout 3 9 Page 2 Section 1 5 Figure 1 within the controller The relay contacts and inputs are assigned func tions through the configuration process The con troller needs to be configured for the individual application Sensor 1 Sensor wire 12V DC output must be screen available for switching Relay contacts cable belden external load relays rated for 4 4 AMPs maximum 8451 or equivalent Reserved for remote enable connection Common relay Common relay connections for connections for Optional for Fire relays 4 and 5 relays 1 to 3 Safety Shut Off Inputs 3 amp 4 reserved for lockout indication Inputs 1 amp 2 reserved for pressure switches 5 BRENNEN e 9 99 9 9 9 ee 9494494 99 9 e e e 9 1283456 43218 54 C 321 C e E INPUTS 12V DC SENSOR INPUTS 12V DC RELAYS RELAYS OUTPUT ee ROBERTS GORDON NEUTRALS BZC 300 INFRANET Comms Connection FIGURE 2 Internal C
3. Ground L e e e 120 V 1 ph 60 Hz e e e LJ 9 9 9 123456 INPUTS 12V DC NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 13 Typical GORDONRAY BH CARIBE and VANTAGE TF Unitary External Wiring Diagram 4 1 1 Description of external wiring diagram 4 1 3 Sequence of operation The external wiring diagram above shows the con a On demand for heat the controller will send nections for three zones of unitary burners Use power to the fan and burners The fan will begin the diagram in conjunction with the configuration operation sheet to identify which relays are to be used for b Once vacuum is established the contacts in the air unitary heaters proving switch inside the burner will close 4 1 2 Description of heaters c The burner will go through a 30 second purge and ROBERTS GORDON Unitary heaters for direct cycle time connection to the controller comprise of the d Once flame is established the heater will remain GORDONRAY BH CARIBE and VANTAGE TF unitary heaters The low voltage jumper at the CARIBE burner must be connected Any heaters sharing a common vent must be con trolled as the same zone in operation until either a lockout condition occurs or the heating is turned off by satisfying tempera ture set point
4. Low voltage separator plate Ground e e e 9 9 123456 SENSOR INPUTS 12V DC OUTPUT INPUTS 12V DC 54 C RELAYS ROBERTS GORDON BZC 300 321 C RELAYS e E ee NEUTRALS NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 16 Typical GORDONRAY DF External Wiring Diagram 4 4 1 4 4 2 Description of external wiring diagram The external wiring diagram above shows the con nections for two zones of GORDONRAY DF heaters The DF burner has both a low and a high fire stage The external relays must be used to acti vate the firing stages Use the diagram in conjunc tion with the configuration sheet to identify which relays are to be used for GORDONRAY DF high and low fire Description of heaters GORDONRAY DF heaters are unitary heaters with two firing stages The high and low fire opera tion is a 24V AC circuit 4 4 3 a Sequence of operation There must be a temperature differential between high and low fire entered under the set up Demand for heat at the low fire stage will occur at the set point temperature displayed on the zone status screen Demand for heat at the high fire stage will occur at a temperature differential below the set point temperature displaye
5. DATE IS 12 10 10 NEWONE Dates must be entered in the format selected See Page 30 Section 6 2 3 Press ENTER when correct The option will now be given to set the day The screen will now show ENTER DAY MON 07 SUN 01 Enter the number for the current day Press ENTER when correct and the display will return to the Set Up Menu Return to Normal Run Mode by pressing RUN If any mistakes were made during the programming sequence see Page 30 Section 6 1 for corrective action 6 3 6 3 1 6 3 2 6 3 3 6 3 4 NOTE 6 3 5 6 3 6 6 3 6 CONTROL SETTINGS After setting the correct time and date it is required to enter the control settings Before altering cali bration settings scroll through zone information screens for each zone and note each zone temper ature sensed by the controller Press PROG Enter code 1805 ENTER Select 1 Data Sensor Calibration The screen will now show CALIBRATION SETTING Each individual ROBERTS GORDON BZC sensor needs to be calibrated after installation First take the temperature reading from zone 1 using an accurate air temperature thermometer Hold the temperature sensing probe close to the sensor Once the temperature has settled note the result Back at the controller enter the number corre sponding to the error recorded to change the cur rent temperature setting The sensed temperature will adjust by 1 degree i
6. SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 2 VANTAGE Il AND VANTAGE HE UNITARY HEATERS ARRANGED IN MULTIPLE ZONES Zone connection detail The power supply for each Zone must be separate from the controller supply e e Burner2 Burner 1 Never directly connect the controller relay terminals to the Burners 1 ph o Individual supply for zone Neutral Live 120V rated for total full load current 120V from relay 3 See Page 7 Section 2 5 for details Zone 3 Zone 2 Zone 1 Sensor Sensor Sensor J gt Sensor wire must be shielded cable Belden 8451 or equivalent lt 12 Line and Low voltage separator plate Zone 3Zone 2 Zone 1 Burner 2 eodein All burners must be connected to Ground Not shown Burner 1 e o o o 9 ee 123456 INPUTS 12V DC SENSOR INPUTS 12V DC OUTPUT 54 C 432158 ROBERTS GORDON F TPALS BZC 300 9 79 a i 321 C RELAYS 9 NOTE LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 14 Typical VANTAGE Il and VANTAGE HE Unitary External Wiring Diagram 4 2 4 Description of external wiring
7. E 4 1Ph RELAYS ad 1 L 120V RELAYS ROBERTS GORDON NEUTRALS 60Hz BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 17 Typical VANTAGE EV External Wiring Diagram 4 5 1 4 5 2 Description of external wiring diagram The external wiring diagram above shows the con nections for three zones of VANTAGE EV sys tems Zone 1 has a separate pump and Zones 2 and 3 share a common pump Use the diagram in conjunction with the configuration sheet to identify which relays are to be used for VANTAGE EV burners and the pumps Description of heaters VANTAGE EV systems comprise of infrared tube heaters connected by manifold pipe to a pump The power to the pump is supplied separately and switched by the controller via a load relay or con tactor Refer to Page 10 Section 3 3 2 for pump alternatives 4 5 3 a Sequence of operation On demand for heat the controller will send power to the pump and burners The pump will begin operation Once vacuum is established the contacts to the air proving switch inside the burner will close The burner will go through a 30 second purge and cycle time Once flame is established the system will remain in operation until either there is demand for heat in another zone connected to the common fan at which point the system will shut down for 30 sec onds to allow
8. For EP 100 or EP 201 pump connection detail refer to Page 18 Figure 19 120V Burner 3 For EP 301 pump connection All burners must be detail refer to Page 20 Figure 21 1 ph connected to Ground 60Hz Load Relay not shown or Burner 2 Contactor 9 Individual supply for pump and blower rated for total full load current See Page 7 Line and Burner 1 Sections 2 3 and 2 4 for details Low voltage separator plate Sensor wire and input wire must be shielded cable Belden 8451 or equivalent Zone 1 Sensor Pressure switch located at outside air blower Pressure switch yell located at vacuum C pump Hr Llc d ke 2e 123 456 49 19 54 C INPUTS 12V DC SENSOR ee 12V DC RELAYS OUTPUT 5 321 C 9 9 L RELAYS ROBERTS GORDON NEUTRALS BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 25 Typical 1ph Pump with Outside Air Blower External Wiring Diagram 12V DC Switching 4 13 1 Description of external wiring diagram For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 The external wiring diagram above shows the con Section 4 5 for detailed sequence of operation nec
9. WHAT IS A ROBERTS GORDON BZC CONTROLLER The ROBERTS GORDON BZC 300 is a micro processor based controller designed for the most efficient control of CORAYVAC VANTAGE GORDONRAY and CARIBE heaters This controller is capable of giving control outputs from 5 relays 3 of which afford heating zone con trol capabilities The controller also features 6 inputs which are used for signal condition monitor ing GENERAL REQUIREMENTS The ROBERTS GORDON BZC series of con trollers are supplied pre configured for their appli cation and only for the use with ROBERTS GOR DON infrared heating equipment Failure to com ply with the installation instructions and configura tion may invalidate the limited warranty set out on Page 39 Section 9 The controller burners pump and outside air blower must be electrically grounded in accor dance with the National Electrical Code ANSI NFPA 70 latest revision Before proceeding with the installation of the con troller it will be necessary to check the following points have been considered CHECK INSTALLATION MATERIALS Switchable Loads The controller relays are rated for switching loads no greater than 4 4A Therefore each zone must have a local relay with contacts rated for the applic able load if it exceeds 4 4A All pumps require the use of an external load switch either a relay or contactor See Page 7 Section 2 3 to ensure the correct one is fitted for each motor ratin
10. 01 The above screen indicates that the pump output selected for the pump is relay 5 See Page 6 Section 1 9 for relay assignments In the case of CORAYVAC the input is used for the pressure switch proving facility It is not used for the VANTAGE EV system After scrolling through all the zone configuration screens the following screen will be displayed IN5 LOCKOUT 00 FIRE OFF 01 01 The screen displayed above indicates that fire safety shut off has been selected for this controller This means that input 5 is already assigned Press ENTER to proceed to the next screen TEMP UNITS C 00 F 01 01 The above screen indicates the units of measure selected for temperature indication for the con troller This setting will effect all default tempera tures Pressing ENTER will proceed to the follow ing screen ENTER STATION NUMBER 00 If there is no PC link to the controller the screen will read as displayed above If an on site PC link is set up then the outstation number will be preset The outstation number will be used by the PC to identi fy which controller it is communicating with See Page 6 Section 1 9 Configuration to check outsta tion number Pressing ENTER will take you back to the set up menu Press RUN to return to the Normal Run Mode from the menu P SECTION 7 TROUBLESHOOTING IMPORTANT Troubleshooting only to be carried out by an elec trician qualified in the in
11. 7 Section 2 3 for settings If problems persist refer to the troubleshooting guide in the Installation Operation and Service manual supplied with the heating equipment If any step is unclear please contact your ROBERTS GORDON independent distributor or Roberts Gordon at 716 852 4400 or 800 828 7450 in the U S 905 945 5403 in Canada or at www rg inc com 25 RoBERTS GorRDON BZC 300 INSTALLATION MANUAL 5 2 1PH PUMP TRIP INDICATION FOR CORAYVAC AND VANTAGE EV SYSTEMS Vacuum Pump IEC contactor and overload rated for the pump motor Never directly connect the controller relay terminals to the pump motor The power supply for each pump must be separate from the controller supply 120V 1Ph 60Hz eet Sensor wire and input wire must be shielded cable Belden 8451 or equivalent Zone 1 Sensor for details Line and Low voltage separator plate Pressure switch located at vacuum Individual supply for pump rated for total full load current See Page 7 Section 2 3 Zone 1 11 Burner 4 All burners must be connected to Ground not shown Burner 3 Burner 2 Burner 1 Veseti 43218 2 secondes 12V DC OUTPUT 123 456 INPUTS 12V DC 54 C RELAYS 321 C ROBERTS GORDON BZC 300
12. Controller Operation Manual CORRECTING WRONG ENTRIES If a wrong entry is made during the programming sequence continue following the instructions until the prompt returns to the menu The entry can be corrected by repeating the pro gramming sequence from the beginning Skip each correct screen by pressing ENTER When the incorrect entry is reached type in the cor rect entry and press ENTER Continue pressing ENTER to skip any following correct screens until the screen prompts you to return to the menu screen CHECK THE TIME AND DATE ON THE STATUS SCREEN Using the SCROLL key scroll through the display screens until the status screen is displayed MON 14 15 32 15 03 98 NND If the time and date displayed are incorrect follow the sequence below to alter them 6 2 2 6 2 3 6 2 4 6 2 5 6 2 6 6 2 7 Press PROG Enter code 0000 ENTER Select 2 Time The screen will be similar to below requesting the selection of the correct date format DATE d m y lt 00 gt m d y 01 00 Type 01 and press ENTER here to change the date format to month day year Alternately pressing ENTER here will leave the date format set as the default day month year The screen will now show TIME IS NEW TIME Enter a new time in Hours Minutes in 24 hour clock notation Mistakes may be rectified by pressing DEL Press ENTER when new time is correct The screen will now show
13. Yes gt ROBERTS GORDON Independent Distributor No No Re fit See Page 38 Figure 35 ITEMS 8 amp 12 Contact ROBERTS GORDON at www rg inc com Contact ROBERTS Contact GORDON your ROBERTS GORDON at www rg inc com Independent Distributor Open cover and view low voltage LED Is it Y lit See Page 38 es Figure 35 ITEM 7 Does appear for NI the current temperature Yes in every zone Check sensor cable Is it Belden 8451 or dl Are any of the mounting Screw heads in contact with the back of the sensor PCB board Are all the connections tight Yes including the shield countersunk screws Figure 35 ITEM 6 No Yes Replace cable with Replace valage Belden 8451 Re establish connections Replace the mounting 10000203 See Page 38 or equivalent screws with Check sensor cable Y Is it Belden 8451 or pica Does 22 appear for the current temperature in one zone Are all the connections tight mi the shield Replace input chip P N 10000400 See Page 38 Figure 35 ITEM 13 Are any of the mounting Screw heads in contact with the back of the sensor PCB board A No Troubleshoot ends FIGURE 32 Sensor Troubleshooting Diagram countersunk screws E cable with ue Belden 8451 or Re est
14. and replace the cover of the controller by replacing the four securing screws 100000203 Low Voltage Fuse Sensor 315mA This low voltage fuse protects the sensors connect ed to the controller circuit board If the low voltage fuse needs replacing the follow ing steps must be taken Turn off the power to the controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the fuse on Page 38 Figure 35 ITEM 6 and remove the fuse with a fuse pulling tool Replace with a new fuse rated at 500mA quick blow Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws Low Voltage LED The LED is linked to the 12V DC output which sup plies the sensors with power If the LED is not lit there will be no 12V DC output resulting in the loss of sensor readings If this is the case the low voltage fuse protecting the sensors Page 38 Figure 35 ITEM 6 will need replacing 39 RoBERTS GorDON BZC 300 INSTALLATION MANUAL 8 2 8 8 2 9 8 2 10 40 10000300 Timekeeper MT48T02 The timekeeper is where the controllers settings are stored If the need arises that you have to take out the timekeeper the following steps must be taken Turn off the power to the controller Remove the clips and screws from th
15. controller relay terminals to the pump motor The power supply for each E pump must be separate from the controller supply For EP 100 or EP 201 pump connection detail refer to Page 17 Figure 18 For EP 301 pump connection detail refer to Page 19 Figure 20 Sensor wire and input wire must be shielded cable Belden 8451 or equivalent Zone 1 t3S Low voltage separator Vacuum Pump All burners must be connected to the Ground not shown Load relay or Contactor For burner lockout indication wiring Burner4 the burners must be wired in series Burner 3 Burner 2 Burner 1 plate A Ground 123456 54 43218 SENSOR INPUTS 12V DC OUTPUT INPUTS 12V DC ROBERTS GORDON EUTPALS RELAYS 331 C E RELAYS 4 BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 28 Typical Burner Lockout Indication External Wiring Diagram 5 3 1 Details of External Wiring Diagram The burner lockout indication wiring diagram shown above refers to the CORAYVAC System configura tion For this option lockout indication wiring to the burners must be done in series Burner lockout indication wiring into 12V DC input
16. cost the following IEC contactors and enclosures required for connection of the EP 301 pump to the con troller the part numbers are listed below For wiring diagrams of the EP 301 pump with the controller see Page 19 Section 4 8 and Page 20 Section 4 9 For 120V AC Connection P N Description 10050006 Contactor 120V AC EP 301 1ph 10001705 Contactor IEC 16A 120V AC 10001001 Enclosure IEC metal 8 x 5 x 5 Nema For 12V DC Connection P N 10050007 10001704 10001001 Description Contactor 12V DC EP 301 1ph Contactor IEC 16A 12V DC Enclosure IEC metal 8 x 5 x 5 Nema 3 3 5 Cable requirements Line power supply As per individual building specification for class of cable to be used Use copper conductors only To size the cable use the amperages of the burners given on Page 9 Section 3 3 1 for each individual zone 12V DC supply to relay boxes and contactors The low voltage output cable must be rated for up to 250V The cable does not have to be shielded The limit on distance is the voltage drop which occurs due to the resistance of the cable Maximum current available is 315 mA 12V DC inputs including sensors Shielded cable Belden 8451 General Cable C2514 or equivalent See Page 11 Section 3 3 5 Figure 10 for an illustration of the shielded cable minimum specification to be used Uninsulated Shield Wire Min 250V insulation Foil Shield 22 AWG Min Stranded conductor White posit
17. diagram 4 2 8 Sequence of operation The external wiring diagram above shows the con a On demand for heat the controller will send power nections for three zones of unitary burners via a to the fan and burners The fan will begin opera load relay Use the diagram in conjunction with the tion configuration sheet to identify which relays are to b Once vacuum is established the contacts in the be used for unitary heaters air proving switch inside the burner will close 4 2 2 Description of heaters c The burner will go through a 30 second purge and ROBERTS GORDON Unitary heaters for indirect cycle time connection to the controller comprise of the VAN d Once flame is established the heater will remain TAGE II and VANTAGE HE unitary heaters The connection shown on Page 13 Section 4 2 Figure 14 should also be used for a zone of CARIBE GORDONRAY BH or VANTAGE TF if the total zone requirement exceeds 4 4A The low voltage jumper at the CARIBE burner must be connected Any heaters sharing a common vent must be con trolled as the same zone in operation until either a lockout condition occurs or the heating is turned off by satisfying tempera ture set point 13 RoBERTS GorDON BZC 300 INSTALLATION MANUAL 4 3 UNITARY HEATERS ARRANGED IN MULTIPLE ZONES WITH CONTROL VIA A 12V DC RELAY Zone Connection Detail e e Burner 2 Burner 1 Never directly connect the controller relay terminal
18. for Burner 4 All burners must be connected to Ground not shown Burner 3 Burner 2 Burner 1 25 Pressure switch located at vacuum pump i Line and Low voltage separator plate r Ground ee 8 1 9 9 e e e 23 4 5 6 INPUTS 12V DC 12V DC OUTPUT SENSOR INPUTS er 54 C 321 C RELAYS RELAYS e E ROBERTS GORDON NEUTRALS BZC 300 a NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 21 Typical EP 301 Pump Contactor External Wiring Diagram 12V DC switching 4 9 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system The power to the EP 301 pump is supplied separately and switched by the controller via a contactor with a 12V DC coil Refer to Page 10 Section 3 3 2 for pump alternatives For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 Section 4 5 for detailed sequence of operation See Page 7 Section 2 3 for correct overload rating 20 SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 10 EP 203 AND EP 303 3PH PUMP CONNECTION 120V AC COIL Vacuum Pump Never directly connect the controller relay terminals to the pump mo
19. hardware in a safe place for refitting after the external wiring con nections have been made Position the controller Page 8 Section 3 2 4 Figure 7 shows the mount ing hole locations Remove the knockouts in the cable entry plate 4 x DIA 0 2 5 mm 174 mm 10 7 272 mm FIGURE 7 Mounting Hole Layout 3 2 6 3 2 7 3 2 8 3 2 9 3 2 10 required for the conduit entry into the controller Fit the cable entry plate provided with the con troller in the slot at the top of the panel Affix the Quick Start Programming Guide P N 10001600 to the wall adjacent to the panel Use the configuration sheet Page 6 Section 1 9 to identify the electrical terminal connections to be made If unsure refer to Pages 2 5 Sections 1 5 to 1 8 for worked example When you are completely familiar with the configu ration of the ROBERTS GORDON BZC 300 con troller to be installed refer to Section 4 starting on Page 12 for typical external wiring diagrams The controller is supplied with 3 separator plates installed The separator plates are shown on Page 8 Section 3 2 10 Figure 8 12V DC low voltage terminals E Line or low voltage _ relay terminals d 120V AC Line voltage terminals FIGURE 8 Separator Plate Detail SECTION 3 INSTALLATION Two separator plates must be removed so that 3 3 ELECTRICAL INSTALLATION REQUIREMENTS one plate remains separating low
20. heaters for indirect connection to the controller using 12V DC wiring comprise of the VANTAGE II HE TF CARIBE and GORDONRAY BH unitary heaters The low voltage jumper at the CARIBE burner must be connected Any heaters sharing a common vent must be con trolled as the same zone 4 3 3 a Sequence of operation On demand for heat the controller will send power to the fan and burners The fan will begin opera tion Once vacuum is established the contacts in the air proving switch inside the burner will close The burner will go through a 30 second purge and cycle time Once flame is established the heater will remain in operation until either a lockout condition occurs or the heating is turned off by satisfying tempera ture set point 4 4 Sensor wire must be shielded cable Belden 8451 or equivalent P External relay 96 SECTION 4 TYPICAL EXTERNAL DIAGRAMS GORDONRAY DF UNITARY HEATERS ARRANGED IN MULTIPLE ZONES Burner 4 To coil for High To coil for Low All burners must be connected to Ground Not shown Zone 1 Burner 3 Burner 2 Burner 1 i4 fire relay zone 2 fire relay zone 2 T3211 D AL Zone 1 Sensor f a X 4PDT High 5 E 4 Fire External Relay 4PDT Low Fire Line and
21. is not required See Page 16 Section 4 5 for detailed sequence of operation See Page 7 Section 2 3 for correct overload rating 21 RoBERTS GorDON BZC 300 INSTALLATION MANUAL 4 11 EP 203 AND EP 303 3PH PUMP CONNECTION ALTERNATIVE 12V DC COIL Vacuum Pump Never directly connect the controller relay terminals to the pump motor IEC contactor and 16 Zone 1 overload rated for mad pump motor gt Burner4 All burners must be connected to Ground The power supply for each not shown pump must be separate from the controller supply Burner 3 Burner 2 e o 230V Individual supply for pump rated for Sensor wire and input wire total full load current B 1 must be shielded 3Ph See Page 7 Section 2 3 uid cable Belden 60Hz for details 8451 or equivalent Zone1 s Li d Pressure switch ine an located at vacuum Sensor e Low voltage pump separator o plate e 949 9 9 9 9 ee EA ees e 8 d 4321S 154 C 321 C INPUTS 12V DC SENSOR INPUTS RELAYS RELAYS d ROBERTS GORDON NEUTRALS BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 23 Typical 3ph Pump Starter External Wiring Diagram 12V DC switch
22. will affect all zones where switching times have not been programmed into the controller When the BMS time enable is activated the lower line of the status screen on the controller will dis play D D D indicating a day period in each of the zones 28 SECTION 5 ALARM SIGNAL CONDITION MONITORING 5 5 FIRE SAFETY SHUT OFF FACILITY Fire Alarm system Alarm On Contacts NC C NO 999 CUN Input wire must be shielded cable Belden 8541 or equivalent eee 9 ee lx 5 6 Reon net aioe 321 C INPUTS 12V DC SENSOR INPUTS RELAYS RELAYS 3s ROBERTS GORDON BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 30 Fire Safety Shut Off External Wiring Diagram The fire safety shut off diagram shown above is a facility available as an option on the ROBERTS GORDON BZC 300 Controller 5 5 1 Further Information The fire safety shut off facility is only available on input 5 If it is required for your application it is pre configured by Roberts Gordon or a ROBERTS GORDON independent distributor prior to ship ping The fire safety shut off signal will immediately dis able all heating zones When the fire alarm is reset contacts restored to the normally open position the heating equipment will attempt to resume nor mal operation When the fire safe
23. 1 2 General Requirements 1 Connection Alternative 12V DC Coil 24 1 3 Check Installation Materials 1 5 Alarm Signal Condition Monitoring 25 x doe nomen 1 5 1 3ph Pump Trip Indication 25 1 5 Example Site Layout Rcs 2 5 2 1ph Pump Trip Indication 26 1 6 Internal Connection Information 3 5 3 Burner Lockout Indication for CORAYVAC 1 7 How to Read the Configuration Sheet 4 Systems 27 1 8 Example Layout Wiring Information 5 5 4 Building Management Remote 1 9 ROBERTS GORDON BZC 300 Time Enable 0005 28 6 5 5 Fire Safety Shut Off Facility 29 2 Specifications C Tm 7 6 Engineer s Set Up a a a a MD 30 2 1 Material Specification 7 6 1 Correcting Wrong Entries 30 2 2 Electrical Specification 7 6 2 Time and Date Set Up 30 2 3 Pump Starter Specification 7 6 3 Control Settings x cx eet REFER EX 31 2 4 Outside Air Supply Blower 7 6 4 Zone Time and Temperature Settings 32 2 5 Burner Electrical Ratings 7 6 5 How to Check the Configuration 34 2 6 Keypad Layout 05 7 7 Troubleshooting 35 3 Installation llle 8 7 4 Display Problems 35 3 1 Preparation cece eee e
24. 5 Keypad Layout P SECTION 2 SPECIFICATIONS MATERIAL SPECIFICATION 2 1 2 2 2 3 Enclosure Material Weight Dimensions Protection ABS UL 94 5VA Rated 3 5 Ibs 1 6 Kg 7 8 x 2 4 x 11 4 199 x 62 x 220mm Rating IP20 ELECTRICAL SPECIFICATION Supply Relay Outputs 12V DC Inputs Sensors Network Battery Back up 120 AC 1ph 1096 50 60Hz 20A Single pole 4 4A 120V AC resistive Only use shielded cable rated for up to 300V Belden 8451 Only use ROBERTS GORDON BZC sensors wired with shielded cable Belden 8451 RS 485 wired using shielded cable Belden 8451 Lithium cell maintains data memory and time clock for 10 years minimum at 77 F 25 C PUMP STARTER SPECIFICATION EP 100 Pump EP 201 Pump EP 203 Pump EP 301 Pump EP 303 Pump Full load current 1ph 3ph 1 3HP 48A NA 3 AHP 6 6A N A 3 4HP N A 3 0A 1 1 2HP 16 0A N A 1 1 2HP N A 42A 2 4 2 5 2 6 SECTION 2 SPECIFICATIONS BZC 300 this cover OUTSIDE AIR SUPPLY BLOWER 2 2A Run Full load current at 120V 60 Hz 1ph 0 2A BURNER ELECTRICAL RATINGS GORDONRAY BH 120V 60Hz 1ph 1A GORDONRAY DF 120V 60Hz 1ph 1A CARIBE 120V 60Hz 1ph 1A VANTAGE TF 120V 60Hz 1ph 1A VANTAGE II or HE VANTAGE EV CORAYVAC KEYPAD LAYOUT LCD Readout Increase Temperature Set Point Decrease Temperature Set Point Enter Information Delete Scroll Forward Return to Run Mode Enter Program Mode Tim
25. 54 C 321 C LL 120V E INPUTS 12V DC SENSORINPUTS 12VDC RELAYS RELAYS c 1ph OUTPUT DH ROBERTS GORDON NEUTRALS BZC 300 NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 24 Typical 1ph Pump with Outside Air Blower External Wiring Diagram For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 4 12 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system EP 100 EP 201 or EP 301 1ph pumps with an outside air blower The power to the pump is supplied sep arately and switched by the controller via a load relay for EP 100 or EP 201 or contactor for EP 301 For other pumps with an outside air blower use the Live from the panel to power the blower and Switch the contactor for the pump Section 4 5 for detailed sequence of operation Refer to Page 10 Section 3 3 2 for pump alterna tives Refer to Page 7 Section 2 3 for correct overload rating 238 RoBERTS GonpoN BZC 300 INSTALLATION MANUAL 4 13 OUTSIDE AIR BLOWER WITH 1PH PUMP CONNECTION ALTERNATIVE 12V DC COIL Outside Air Vacuum Pump Blower Zone 1 e Burner4 The power supply for each Never directly connect the pump must be separate controller relay terminals to from the controller supply the pump motor
26. FIGURE 4 Example External Wiring Diagram RoBERTS GonpoN BZC 300 INSTALLATION MANUAL 1 9 ROBERTS GORDON BZC 300 CONFIGURATION Controller Serial Number Project Name Roberts Gordon Layout Drawing Number TABLE OF OUPUTS OUTPUT ZONE NO PUMP NO PRODUCT EXTERNAL RELAY Y N SECTION NO D P 1 9 1 Key to product definitions UNIT GORDONRAY BH unitary heater UNIT VANTAGE TF unitary UNIT CARIBE unitary heater UNIT VANTAGE II or HE unitary heater HILO GORDONRAY DF unitary heater C FAN VANTAGE EV System CRV CORAYVAC Continuous system 1 9 2 Key to input definitions P S CORAYVAC system pressure switch for each individual pump P T Pump trip indication for one zone F S Fire safety shut off option available on input 5 only 1 9 3 Configured By Date TABLE OF INPUTS ZONE NO PUMP NO PRODUCT SECTION NO Reserved for BMS time enable Outstation number aM Key to Outstation reference If the ROBERTS GORDON BZC 300 is set up for use on site with a PC link an outstation number will be assigned during configuration The default set ting is 00 for no communications ROBERTS GORDON Quality in Any Language U S A 1 716 852 4400 Canada 1 905 945 5403 U K e 44 0 1902 494425 Internet www rg inc com WARNING Disconnect from electrical supply before removing FIGURE
27. I RELAYS Ll NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 27 Typical 1ph Pump Trip Indication External Wiring Diagram 5 2 1 NOTE 26 Details of Operation The pump trip wiring diagram shown above refers to the CORAYVAC and VANTAGE EV system configurations An overload with normally open con tacts is required A typical IEC contactor and over load is shown on Page 26 Section 5 2 Figure 27 The pressure switch is not required for VANTAGE EV systems If pump trip occurs the zone display on the con troller will show HEATER LOCKOUT followed by the zone number on the status screen Indication will show that the overload has tripped 5 2 2 Further Information The overload must be manually reset Check and adjust the overload if required refer to Page 7 Section 2 3 for settings If problems persist refer to the troubleshooting guide in the Installation Operation and Service manual supplied with the heating equipment If any step is unclear please contact your ROBERTS GORDON independent distributor or Roberts Gordon at 716 852 4400 or 800 828 7450 in the U S 905 945 5403 in Canada or at WWW rg inc com 5 3 SECTION 5 ALARM SIGNAL CONDITION MONITORING BURNER LOCKOUT INDICATION FOR CORAYVAC SYSTEMS Pressure switch Sensor located at vacuum pumps Line and Never directly connect the
28. ONE TIME AND TEMPERATURE SETTINGS The factory defaults are as follows Temperature Settings Day Temperature 68 F or 20 C Night Temperature 58 F or 4 C Time Settings NONE Switching Times NONE If Remote Time Enable is to be used leave all switching periods set to the default To alter the factory default settings follow the instructions below Press PROG Enter code 0000 ENTER Select 1 Data Each zone can have individual time and tempera ture settings therefore this procedure must be repeated for each zone to be set up The screen will now show ENTER REQUIRED DAY TEMP 68 Press 2 digits for the required DAY temperature and then press ENTER The screen will now show ENTER REQUIRED NIGHT TEMP 58 Press 2 digits for the required NIGHT temperature and then press ENTER The screen will now show DAY PERIOD 1 MON E 00 00 S 00 00 Enter required switching times for Monday period 1 There are 4 switching periods per day for each indi vidual zone The following example allows for one switching period per day START 08 00 END17 00 START 08 00 END12 00 NO SWITCHING PERIOD Monday to Friday Saturday Sunday Enter start time 0800 Use 24 hour clock notation for the start and end times of DAY TEMPERATURE mistakes may be rectified by pressing DEL and then press ENTER When entering a start time it is not necessary to allow a warm up period prior to the start of the requir
29. ROBERTS GORDON ROBERTS GORDON BAL S00 CONTROLLER Installation Manual A WARNING Installer Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the installation and operation manuals thoroughly before installing or servicing Owner this equipment Keep this manual in a safe place to provide your Installation must be done by a electrician qualified serviceman with information should it become in the installation and service of control systems necessary for heating equipment Roberts Gordon Roberts Gordon Canada Inc 1250 William Street 241 South Service Road West P O Box 44 Grimsby Ontario L3M 1Y7 Canada Buffalo New York 14240 0044 Telephone 905 945 5403 Telephone 716 852 4400 Fax 905 945 0511 Fax 716 852 0854 Toll Free 800 828 7450 C us http www rg inc com Roberts Gordon Oxford Street Bilston West Midlands WV 14 7EG UK LISTED Telephone 44 0 1902 494425 Fax 44 0 1902 403200 Quality in Any Language Copyright 2001 Roberts Gordon 10031601NA Original Issue 06 00 P TABLE OF CONTENTS 1 Introduction 4 12 Outside Air Blower with 1ph 1 1 What is a ROBERTS GORDON BZC Pump Connection 23 Controller 0 2 2020 1 4 13 Outside Air Blower with 1ph Pump
30. Road West Grimsby Ontario L3M 1Y7 Telephone 905 945 5403 Fax 905 945 0511 On the web at www rg inc com Roberts Gordon s liability and your exclusive remedy under this warranty or any implied warranty including the implied warranties of merchantability and fitness for a particular purpose is limited to providing replace ment parts during the term of this warranty Some juris dictions do not allow limitations on how long an implied war ranty lasts so this limitation may not apply to you There are no rights warranties or conditions expressed or implied statutory or otherwise other than those contained in this warranty Roberts Gordon shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the ROBERTS GORDON BZC 300 Controller Some jurisdictions do not allow the exclusion or limitation of inci dental or consequential damages so this limitation or exclu sion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Roberts Gordon shall not be responsible for failure to per form under the terms of this warranty if caused by circum stances out of its control including but not limited to fire flood strike government or court orders unavailability of supplies parts or power No person is authorized to assume for Roberts Gordon any other wa
31. T ROBERTS GORDON NEUTRALS BZC 300 e e 23456 INPUTS 12V DC 9 54 C RELAYS NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 20 Typical EP 301 Pump Contactor External Wiring Diagram 4 8 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system The power to the EP 301 pump is supplied separately and switched by the controller via a contactor with a 120V AC coil Refer to Page 10 Section 3 3 2 for pump alternatives For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 Section 4 5 for detailed sequence of operation See Page 7 Section 2 3for correct overload rating 19 RoBERTS GorRDON BZC 300 INSTALLATION MANUAL 4 9 EP 301 Vacuum Contactor P N 10050007 rated for the EP 301 1PH PUMP CONNECTION ALTERNATIVE 12V DC COIL Pump Never directly connect the controller relay terminals to the pump motor Zone 1 EP 301 pump motor ee The power supply for each pump must be separate from the controller supply 120V en 1Ph 60Hz eet Individual supply for pump rated Sensor wire and input wire must be shielded cable Belden 8451 or equivalent Zone 1 for details Sensor total full load current See Page 7 Section 2 3
32. ablish connections eplace the mounting equivalent screws with 35 RoBERTS GoRDON BZC 300 INSTALLATION MANUAL 7 3 UNITARY BURNERS Adjust set point to call for heat See Page 37 Section 7 6 for Y L Does the burner b attempt ignition No 9 Does the burner come on Does the burner A remain lit No E Troubleshoot ends No ROBERTS GORDON Independent Contact your ROBERTS ou ee bl S iau D Check EAS configurati Page 34 Section 6 5 Is the correct LED on See Page 38 Figure 35 ITEM 2 om Yes Contact your AI Independent ud X Is the polarity of nes External wiring ib ES your ne ROBERTS GORDON FIGURE 33 Unitary Troubleshooting Diagram 7 4 TROUBLESHOOTING VARIATIONS FOR No Contact ROBERTS GORDON at www rg inc com AJ Is external wiring to the Y burner OK ib Rectify Contact ROBERTS GORDON at www rg inc com Rectify Contact ROBERTS GORDON at www rg inc com Contact your ROBERTS GORDON Independent Distributor Contact ROBERTS GORDON at www rg inc com VANTAGE EV SYSTEMS If there is power from the panel to energize the starter but the pump fails to run check the overload setting at the local starter Refer to Page 7 Section 2 3 for detai
33. and line volt d A WARNING Page 9 Section 3 2 10 Figure 9 shows the sepa rator plate detail for an installation where relays 1 to 3 switch line voltage and relays 4 and 5 switch low voltage 12V DC The 2 un used separator plates must be discard ed Electrical Shock Hazard Field installed 12 V DC Disconnect electrical power before servicing low voltage links Voltage separator plates This appliance must be connected to a properly grounded electrical source Field installed 120 V AC line voltage links Failure to follow these instructions can result in death or electrical shock 3 3 1 The panel should be supplied from a local fused isolator rated for a total amperage not exceeding 20A If the total current load exceeds the isolator rating the power to the burners can be switched by using a local relay See Page 13 Section 4 2 and Page 14 Section 4 3 for alternate methods 12V DClow voltage terminals The method for calculating the current loading is as follows ELA GORDONRAY BH 1 A burner GORDONRAY DF 1 A burner CARIBE 1 A burner VANTAGE TF 1 A burner VANTAGE EV 0 2 A burner CORAYVAC 0 2 A burner Multiply the current for the individual burners above FIGURE 9 Separator Plate Removal Detail by the number of burners supplied from the panel 3 2 11 Reconnect the ribbon cable to the PCB board and to give the total current required The pumps VAN replace the cover o
34. ans graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Roberts Gordon Printed in the U S A TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Example Site Layout Drawing 2 Internal Connection Diagram 3 Example Configuration Table 4 Example External Wiring Diagram 5 7 ROBERTS GORDON BZC 300 Cover Detail 8 Mounting 8 Separator Plate Detail 8 Separator Plate Removal Detail 9 Shielded Cable Detail 11 6 11 Mounting 11 GORDONRAY CARIBE and VANTAGE Unitary External Wiring Diagram 12 VANTAGE II and HE Unitary External Wiring Diagram 1255 eb eet weer Eni iS 13 Alternate Unitary External Wiring Diagram 2 14 GORDONRAY DF External Wiring Diagram uc oso EP VE pea Ria ees 15 VANTAGE EV External Wiri
35. cable from the main board only leaving the ribbon attached to the cover Locate the input chip from Page 38 Figure 35 ITEM 16 and with a chip pulling tool remove the input chip out of the socket To fit a new input chip Carefully insert the chip orientating it the same as the original chip was Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws 41 SECTION 9 THE ROBERTS GonpoN BZC 300 CONTROLLER WARRANTY P SECTION 9 THE ROBERTS GORDON BZC 300 CONTROLLER WAR RANTY ROBERTS GORDON WILL PAY FOR For 36 months from the date of purchase by the original consumer or 42 months from date of shipment by Roberts Gordon whichever occurs first we will provide free of charge replacement parts for any part of the ROBERTS GORDON BZC 300 Controller that fails because of a man ufacturing or material defect ROBERTS GORDON replacement parts are warranted for the period of the original ROBERTS GORDON BZC 300 Controller Warranty ROBERTS GORDON WILL NOT PAY FOR Service trips service calls and labor charges Shipment of replacement parts Damage due to Failure to install operate or maintain the ROBERTS GORDON BZC 300 Controller as directed in the Installation and Operation Manuals You must follow requirements printed in these manuals Misuse abuse neglect or modification of the ROBERTS GORDON BZC 300 Controller in any way Improper ser
36. cted via a load relay to RL5 see Page 5 Section 1 8 Figure 4 In the column labeled EXTERNAL RELAY Y N there is a Y indicating that the load for the pump is greater than 4 4A A load relay or contactor 1ph motors or starter 3ph motors must be provided to switch the load of the pump Inputs 1 to 3 are assigned for the pressure switch es where input 1 will be connected to the pressure switch in Zone 1 TABLE OF INPUTS ZONE NO PUMP NO PRODUCT SECTION NO U op AR RS A Reserved for BMS time enable Key to input definitions P S P T F S BMS CORAYVAC system pressure switch for one or more zones Pump trip for one zone Fire safety shut off option available on input 5 only Building Management System SECTION 1 INTRODUCTION 1 8 EXAMPLE LAYOUT WIRING INFORMATION The external wiring diagram shown below repre sents the external wiring required for the example site layout on Page 2 Section 1 5 Figure 1 The information on the configuration tables for out puts and inputs determines the connection required The product specific wiring arrangements are found starting on Page 12 Section 4 For the external wiring shown below see the typi cal CRV zone wiring diagram Page 17 Section 4 6 For the UNIT zone wiring see Page 12 Section 4 1 EP100 or EP201 pump connection detail Vacuum Pump Ne
37. d on the zone status screen The burner will go through a 30 second purge and cycle time Once flame is established the system will remain in operation until either a lockout condition occurs or the heating is turned off by satisfying tempera ture set point 15 RoBERTS GonpoN BZC 300 INSTALLATION MANUAL VANTAGE EV SYSTEMS ARRANGED IN MULTIPLE ZONES 4 5 EP100 or EP201 pump connection detail for pump alternatives refer to Page10 Section 3 3 2 Vacuum pump ee Never directly connect the controller relay terminals to 1 20V the pump motor 1Ph 60Hz Individual supply Neutral Live 120V supply for pump rated for 120V from Zon total full load current relay 5 Zone 1 2 amp 3 See Page 7 Section 2 3 for details Pump 1 Pump 2 Sensor wire must be shielded cable Belden Line and 8451 or equivalent Low voltage separator plate Zone 3 Zone 2 Zone 1 Sensor Sensor Sensor The power supply for each pump must be separate from the controller All burners must be connected to Ground Not shown Zone 3 Zone 2 Zone 1 ee oe 9 Burner 4 nes Burner 3 Burner 1 4 Burner 2 Ground L e e N e e oe pee eae Ceara B ee deers INPUTS 12V DC SENSOR ANE 12V DC OUTPUT
38. e Override a Zone 120V 60Hz 1ph 5A 120V 60Hz 1ph 2A 120V 60Hz 1ph 2A Oo ND RON RoBERTS GonpoN BZC 300 INSTALLATION MANUAL P SECTION 3 INSTALLATION 3 1 3 1 1 3 2 3 2 1 3 2 2 Installation of the ROBERTS GORDON BZC 300 Controller and the associated external electrical wiring must be done by an electrician qualified in the installation of control systems for heating equipment PREPARATION Before installing the controller observe the follow ing Ensure that you have a copy of the site layout for the project that clearly identifies the separate zones See example on Page 2 Section 1 5 Figure 1 INSTALLING THE ROBERTS GORDON BZC 300 CONTROLLER Choose a mounting location for the controller Note that the maximum distance to any sensor is 1500 450 m Remove the cover of the controller by removing the four securing screws See Page 8 Section 3 2 2 Figure 6 for cover detail Pry the clip 1 off using a flat blade screw driver in the groove 3 This will reveal the secur ing screw 2 Repeat this for each corner of the controller PN DESCRIPTION 10000701 BZC CLIP COVER PLASTIC 10000700 BZC SCREW M3X22 PAN HD BZP NA LEVER SLOT NA SECURING SCREW HOLE 10030500 BZC300 LID ASSY FIGURE 6 ROBERTS GORDON BZC 300 Cover Detail 3 2 3 3 2 4 3 2 5 Disconnect the ribbon cable from the controller PCB board Place the cover and the
39. e cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the timekeeper on Page 38 Figure 35 ITEM 8 and with a chip pulling tool remove the timekeeper out of the socket To fit a new timekeeper See Page 38 Figure 35 ITEM 8 there is a notch on the socket and the timekeeper The timekeeper should be fit so that the notch on the socket and the timekeeper are aligned Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws Processor Chip The processor is the brains behind the controller The processor is not serviceable 10000800 Comms Chip The comms chip enables the controller to commu nicate with a PC for use with the INFRANET soft ware To remove the comms chip the following steps must be taken Turn off the power to controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the comms chip from Page 38 Figure 35 ITEM 10 and with a schip pulling tool remove the comms chip out of the socket To fit a new comms chip There is a circular indent on one corner of the comms chip See Page 38 Figure 35 ITEM 10 to see the ori entation of the chip Insert chip accordingly Reconnect the r
40. ed day temperature This is automatically cal culated by the controller giving the required tem perature at the time set The screen will now show DAY PERIOD 1 MON S 08 00 E 00 00 Enter end time 1700 Press Enter DAY PERIOD 1 MON S 08 00 E 17 00 The screen will now show DAY PERIOD 2 MON E 00 00 S 00 00 Press ENTER to skip without altering the setting The reason for leaving the start and end times 00 00 is because in this example we are only using one switching period per day Repeat as above for periods 3 and 4 for Monday The screen will now show DAY PERIOD 1 TUE S 00 00 E 00 00 Pressing the PROG key at this point will copy all of Monday s switching times to Tuesday The screen will now show DAY PERIOD 1 WED S 00 00 E 00 00 Pressing the PROG key at this point will copy the times from Tuesday to Wednesday Repeat this for Thursday and Friday The screen will now show DAY PERIOD 1 SAT E 00 00 S 00 00 For Saturday the switching period is different from the weekday settings The new settings must be entered Enter start time 0800 Enter end time 1200 Press ENTER DAY PERIOD 1 SAT S 08 00 E 12 00 Leave the start and end times blank for periods 2 3 and 4 because in this example we are only using one switching period on Saturday As no switching times are required for Sunday press RUN to save the settings and return to the menu The proc
41. ee 8 7 2 Sensor Problems sss 35 3 2 Installing the ROBERTS GORDON 7 3 Unitary Burners xxxi es i RRERES 36 BZC 300 Controller lusus 8 7 4 Variations for VANTAGE EV Systems 36 3 3 Electrical Installation Requirements 9 7 5 CORAYVAC Systems 37 4 Typical External Diagrams 12 7 6 Screen 6 37 4 1 GORDONRAY BH CARIBE and 8 Replacement Parts 38 VANTAGE TF Unitary Heaters 12 8 1 Component 6 38 4 2 VANTAGE Il and VANTAGE HE Unitary 8 2 Replacement Parts Instructions 39 Heaters Load Relay 13 9 The ROBERTS GORDON BZC 300 4 3 Unitary Heaters Load Relay Controller 42 12V DC Coil 2 eee eee 14 4 4 GORDONRAY DF Heaters 15 4 5 VANTAGE EV System 16 4 6 CORAYVAC System 17 4 7 EP 100 and EP 201 1ph Pump Connection 12V DC Coil 18 4 8 EP 301 1ph Pump Connection 120V AC 19 4 9 EP 901 1ph Pump Connection Alternative 12V DC Coil 20 4 10 EP 203 and EP 303 3ph Pump Connection 120V AC Coil 21 4 11 EP 203 and EP 303 3ph Pump Connection 12V DC Coil 22 O 2001 ROBERTSGORDON All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any me
42. eeper are aligned Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws 10000400 ROBERTS GORDON BZC Input Chip 16 Pin PC815 The input chip enables the controller to communi cate with the sensors and 12V DC inputs To remove the input chip the following steps must be taken Turn off the power to the controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the input chip from Page 38 Figure 35 ITEM 13 and with a chip pulling tool remove the input chip out of the socket To fit a new input chip Carefully insert the chip orientating it the same as the original chip was Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws 8 2 14 8 2 15 8 2 16 SECTION 8 REPLACEMENT PARTS 10000702 Cable Entry Plate Not shown 10000703 Clip Cover and Screw 4 pack Not shown 10000401 ROBERTS GORDON BZC Input Chip 8 Pin PC815 The input chip enables the controller to communi cate with the sensors and 12V DC inputs To remove the input chip the following steps must be taken Turn off the power to the controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon
43. ess described above must now be repeat ed for each heating zone within the building Press RUN to return to the Normal Run Mode from the menu If any mistakes were made during the programming sequence see Page 30 Section 6 1 for corrective action SECTION 6 ENGINEER s SET UP 33 RoBERTS GonpoN BZC 300 INSTALLATION MANUAL 6 5 NOTE 34 HOW TO CHECK THE CONFIGURATION OF THE ROBERTS GORDON BZC 300 CONTROLLER The individual configuration can be verified for the control by following the steps described below This is advised where multiple panels are installed on one site Press PROG Enter code 1805 Select 4 C LOG You will then be given the following options 1 CLEAR MONITOR 2 VIEW CONFIG Select 2 to view the original configuration settings pre programmed into the controller The screens displayed will be similar to those below ENTER NUMBER OF ZONES 03 The above screen shows that the controller is set up for three zones Press ENTER to proceed to the next screen Zi 1 U 2 CF 3 HL 4 CRV 5 URV 02 The above screen indicates that zone 1 is selected as a VANTAGE EV or Common Fan System For VANTAGE EV and CORAYVAC there is a further screen to designate the pump outputs If the display had shown 01 UNIT unitary refers to GORDONRAY BH VANTAGE Il VANTAGE HE VANTAGE TF or CARIBE ENTER will scroll the display to the zone 2 set up FAN NUMBER FOR ZONE 1
44. f the controller by replacing the TAGE Il and VANTAGE HE burners do not count 4 securing screws in this calculation because the power must be switched locally via a relay or contactor If the total current load exceeds 4 4A for any relay then a local switching relay must be employed for the burners The total added cur rent load for all 5 relays must not exceed 20A RoBERTS GonbpoN BZC 300 INSTALLATION MANUAL 3 3 2 Pump Requirements The pumps must be isolated separately from the panel The contactor or relay will be energized via an output from the panel switched through the desig Roberts Gordon provides the following IEC contac tor and overload starter packages optional for 1ph pumps to be used if pump trip indication is required see Page 6 Section 1 9 The contents are listed below P N Description 10050002 Starter 12V DC EP 201 1ph 10001001 Enclosure IEC metal 8 x 5 x 5 Nema 10001702 Contactor IEC 12A 12V DC 10001707 Overload IEC 5 0 15 0A 1ph 10050003 Starter 120V AC EP 201 1ph 10001001 Enclosure IEC metal 8 x 5 x 5 Nema 10001703 Contactor IEC 12A 120V AC 10001707 Overload IEC 5 0 15 0A 1ph 10050004 Starter 12V DC EP 301 1ph 10001001 Enclosure IEC metal 8 x 5 x 5 Nema 10001704 Contactor IEC 16A 12V DC 10001708 Overload IEC 12 0 32 0A 1ph 10050005 Starter 120V AC EP 301 1ph 10001001 Enclosure IEC metal 8 x 5 x 5 Nema 10001705 Contactor IEC 16A 120V AC 10001708 Overload IEC 12 0 32 0A 1ph
45. g The total added current load for all 5 relays must not exceed 20A Sensor Location The sensor measures the air temperature in the building It is important that the sensor is located in an area within the heated zone at occupant level The sensor should be located in a position such that it is not shaded from the infrared heating 1 3 3 1 3 4 1 3 5 1 4 SECTION 1 INTRODUCTION Installation Materials Shielded cable Belden 8451 General Cable C2514 or equivalent rated for up to 300V AC must be used for sensors and 12V DC inputs The sensors must be fastened using counter sunk screws Dome headed screws will short out the board and result in failure of the sensor Inputs All inputs into the controller must be 12V DC The supply is from the terminal to be found on the board of the controller Programming Details Every controller is programmed for the specific application Use the site layout drawing to identify the heating zones indicated in the configuration on Page 6 Section 1 9 SAFETY Your Safety is Important to Us This sym bol is used throughout the manual to noti fy you of possible fire electrical or burn hazards Please pay special attention when reading and following the warnings in these sections A WARNING Installation Service and Annual Inspection of controller must be done by an electrician qualified in the installation of control systems for heating equipment Installat
46. ibbon cable to the main board and replace the cover of the controller by replacing the four securing screws 8 2 11 Ribbon Cable Socket The cover of the controller is connected to the main circuit board by means of a ribbon cable When ser vicing the controller you will need to disconnect the ribbon cable Do this by simply pulling the connector from the socket highlighted above It is imperative that the ribbon cable is connected properly before powering up the controller To do this simply ensure both ends the cover and the main board have been firmly pushed into the Sockets The ribbon cable can be connected to the controller one way 8 2 12 8 2 13 10032300 BZC Eprom 300 The Eprom is where the controller s program not settings is stored To take out the Eprom The following steps must be taken Turn off the power to the controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the Eprom on Page 38 Figure 35 ITEM 12 and with a chip pulling tool remove the Eprom out of the socket To fit new Eprom First look at the Eprom you are about to fit You will see a notch on one end of the Eprom See Page 38 Figure 35 ITEM 12 There is a notch on the socket and a notch on the timekeeper The Eprom should be fit so that the notch on the socket and the timek
47. ie Nee gt L 120V i Neopet 54 C 321 C E SENSOR INPUTS 12V DC RELAYS RELAYS OUTPUT ROBERTS GORDON NEUTRALS BZC 300 1Ph 60Hz INPUTS 12V DC NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 18 Typical CORAYVAC External Wiring Diagram 4 6 1 Description of external wiring diagram 4 6 3 Sequence of operation The external wiring diagram above shows the con a On demand for heat the controller will send power nections for three zones of CORAYVAC systems to the pump The pump will begin operation Zone 1 has a separate pump and Zones 2 and 3 b Once vacuum is established the contacts to the share a common pump Use the diagram in con f air proving switch at the pump will close junction with the configuration sheet to identify which relays are to be used for CORAYVAC burn c The controller sends power to the burners The ers pumps and pressure switches burners will go through a 45 second purge and cycle time 4 6 2 Description of heating system d Once flame is established the heater will remain in operation until either a lockout condition occurs or the heating is turned off by satisfying tempera ture set point CORAYVAC systems comprise of a series of burn ers linked to a common pump The power t
48. ing 4 11 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system The power to the pump is supplied separately and Switched by the controller via a contactor with a 12V DC coil Refer to Page 10 Section 3 3 2 for pump alternatives For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 Section 4 5 for detailed sequence of operation See Page 7 Section 2 3for correct overload rating 22 SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 12 OUTSIDE AIR BLOWER WITH 1PH PUMP CONNECTION Zone 1 Outside Air Blower Pump 1 w Zone 1 The power supply for each Never directly connect the Burner 4 pump must be separate controller relay terminals to the from the controller supply t pump motor All burners must be connected to Ground not shown 120V Burner 3 1ph 60Hz Burner 2 m Sensor wire and input wire Individual supply must be shielded for pump rated for cable Belden total full load current 8451 or equivalent See Page 7 Section 2 3 for details Burner 1 Pressure switch Zone 1 located at outside Sensor Line and air blower Low voltage Pressure switch separator Ground located at vacuum M plate 5 j pumps X L e e 6 e e 6 e 123 4 5 6 4321S
49. ion Service and Annual Inspection must be done by a contractor qualified in the installation and service of gas fired heating equipment Read this manual carefully before installation operation or service of this equipment Failure to follow these instructions can result in death injury or property damage For optimum heater performance and safe heating conditions inspect and maintain heater s before every heating season and as necessary Also know and maintain heater clearances to com bustibles see heater Installation Operation and Service manual for further details If you require additional manuals contact your ROBERTS GOR DON independent distributor or Roberts Gordon at 716 852 4400 or 800 828 7450 in the U S 905 945 5403 in Canada or at www rg inc com RoBERTS GonpoN BZC 300 INSTALLATION MANUAL IMPORTANT READ THIS FIRST 1 5 EXAMPLE SITE LAYOUT Shown below is an example layout for a building It is essential to follow this section to understand where a ROBERTS GORDON BZC 300 Controller how to use the information in this manual will be used to control the infrared heating systems shown Please ensure that you understand this example before proceeding with the installation The layout consists of two zones of CORAYVAC systems and one zone of unitary heaters Four Gas Fired Infrared Unitary heaters arranged in a single zone Wall Mounted Sensor E E
50. ive 22 AWG Min Stranded conductor Black 2 negative FIGURE 10 Shielded Cable Detail 3 3 6 SECTION 3 INSTALLATION Sensor Mounting The sensor measures the air temperature in the building It is important that the sensor is located in an area within the heated zone at occupant level The sensor should be located in a position that is not shaded from the infrared heating as Screw Provided FIGURE 11 Sensor Cover Assembly Do not use mounting holes behind PCB Board Sensor suitable for mounting on a 4 Conduit Box Do not use for mounting Knockouts Knockout for cable entry 1 47 35mm FIGURE 12 Mounting ROBERTS GorRDON BZC 300 INSTALLATION MANUAL P SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 1 GORDONRAY BH CARIBE AND VANTAGE TF UNITARY HEATERS ARRANGED IN MULTIPLE ZONES All burners must be connected to Ground Not shown Zone 3 Zone 2 Zone 1 Burner 4 Burner 3 Zone 3 Zone 2 Zone 1 Sensor Sensor Sensor Burner 2 S rrr eet Der H Burner 1 Sensor wire must be shielded cable Belden 8451 or equivalent ues SI Line and C 5 Low voltage FI separator plate 99 ee ee eee 54 9 e 43215 Toler 321 C SENSOR ERA 12V DC RELAYS RELAYS eee OUTPUT ROBERTS GORDON EVTRA S BZC 300
51. ls 36 IMPORTANT When troubleshooting burner problems always troubleshoot each zone individually 7 5 CORAYVAC SYSTEMS Adjust set point to call for heat See Page 37 Section 7 6 for instructions Check panel configuration Page 34 Section 6 5 Is the correct LED on See Page 38 Figure 35 Is external wiring Does the pump to the pump OK Yes come on SECTION 7 TROUBLESHOOTING Refer to the CORAYVAC Installation Operation and Service Manual or contact your ROBERTS GORDON Independent Distributor Contact ROBERTS GORDONG at www rg inc com Contact ROBERTS GORDONG at www rg inc com Is the overload set correctly 3ph motors only Yes 7 ITEM 2 Rectify e Does the zone XJ Is there continuity N Refer to the CORAYVAC Installation Operation and Service Manual or contact your ROBERTS GORDON Independent Distributor Reset refer to overload settings Page 7 Section 2 3 Check controller configuration Page 34 Section 6 5 Is external wiring relay LED No between the input and Is the correct LED on to the pressure come on the input terminal E Is external wiring to the pressure switch OK Installation Operation No Rectify Ney Does the burner remain lit Is the polarity of Y N the external Rectif
52. n Fahrenheit for each incre ment of change if the units of measure are Centigrade the change will be in degree incre ments After altering allow 5 seconds for the reading to set tle before making further alterations For example if the measured temperature in zone 1 was 65 F and the displayed temperature was 61 F The calibration setting entered should 04 The current temperature will now display 65 F If the reading is showing this means that the sensor is faulty or not connected See Page 35 Section 7 2 for troubleshooting instructions Pressing ENTER will now allow you to alter cali bration 2 The same procedure must be followed for calibrating each of the sensors connected to the controller Maximum Override Adjustments The screen will now show ENTER MAXIMUM 08 OVERRIDE Unless instructed otherwise by the building owner leave at default by pressing ENTER The override is the maximum number of hours that the override button can be made to work Setting this at 00 will disable the override button completely The screen will now show 6 3 7 6 3 8 6 3 9 6 3 10 6 3 11 6 3 12 SECTION 6 ENGINEER S SET UP ENTER UPPER TEMP 05 OFFSET LIMIT Unless instructed otherwise by the building owner leave at default 5 F or 2 C by pressing ENTER This is the number of degrees that the user will be able to increase the set point using the UP ARROW in Normal Run Mode The sc
53. nated relay See Page 6 Section 1 9 for site specif ic configuration Use the table below to select the correct pump exter nal wiring diagram Supply Relay Voltage Coil EP 100 120V iph 120V AC 16 4 5 EP 201 120V iph 120V AC 16 4 5 EP 301 120V iph 120V AC 19 4 8 Pump Page Section EP 100 120V iph 12V DC 18 4 7 EP 201 120V iph 12V DC 18 4 7 EP 301 120V iph 12V DC 20 4 9 EP 203 230V3ph 120V AC 21 4 10 EP 308 230V3ph 120V AC 21 4 10 EP 203 230V3ph 12V DC 22 4 11 EP 303 230V3ph 12V DC 22 4 11 3 3 3 Outside air supply Roberts Gordon provides at an additional cost the If an outside air blower is to be used with any of the following IEC contactor and overload starter pack above options see Page 23 Section 4 12 and ages required for 3ph pumps the contents are list Page 24 Section 4 13 for external wiring dia ed below grams P N Description 3 3 4 Important voltage selection 10050000 10001001 10001700 10001706 10050001 10001001 10001701 10001706 Starter 12V DC EP 203 303 3ph Enclosure IEC metal 8 x 5 x 5 Nema Contactor IEC 9A 12V DC Overload IEC 1 6 5 0A 3ph Starter 120V AC EP 203 303 3ph Enclosure IEC metal 8 x 5 x 5 Nema Contactor IEC 9A 120V AC Overload IEC 1 6 5 0A 3ph The controller can be used with either 120V or 230V 1ph Ensure the voltage selector switch is set to 115V for 120V operation See Page 38 Section 8 Figure 35 ITEM 3 Roberts Gordon provides at an additional
54. ng Diagram 16 CORAYVAC External Wiring Diagram 17 EP 100 and EP 201 1ph External Wiring 12V DC switching 18 EP 301 Pump Contactor External Wiring 19 EP 301 Pump Contactor External Wiring Diagram 12V DC switching 20 3ph Pump Starter External 21 3ph Pump Starter External Wiring Diagram 12V DC switching 22 1ph Pump with Outside Air Blower External 23 1ph Pump with Outside Air Blower External Wiring 12V DC switching 24 3ph Pump Trip Indication External 25 1ph Pump Trip Indication External Wiring 26 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Burner Lockout Indication External BMS Remote Time Enable External Wiring Fire Safety Shut Off External Wiring Diagram llle Display Troubleshooting Diagram Sensor Troubleshooting Diagram Unitary Troubleshooting Diagram CORAYVAC Troubleshooting Diagram ROBERTS GORDON BZC 300 Internal Components Diagram ROBERTS GORDON BZC 700 INSTALLATION MANUAL P SECTION 1 INTRODUCTION 1 1 1 2 1 3 1 3 1 1 3 2
55. o the pump is supplied separately and switched by the controller via a load relay or contactor Refer to E Page 10 Section 3 3 2 for pump alternatives e After the heating is turned off the pump will con tinue operation for a 2 minute post purge 17 RoBERTS GonpoN BZC 300 INSTALLATION MANUAL 4 7 EP 100 AND EP 201 1PH PUMP CONNECTION 12V DC COIL Vacuum Pump Zone 1 The power supply for each ee Burner 4 pump must be separate from the controller supply Never directly connect the controller relay terminals to the pump motor 1 20V Burner 3 iph 60Hz2 All burners must be connected to Ground Burner 2 not shown Sensor wire and Individual supply input wire must be for pump rated for shielded cable Belden total full load current Line and Burner 1 Pressure switch 8451 or equivalent See Page 7 Section 2 3 Low voltage i separator located at vacuum for details blate Zone 1 Sensor e 0 9 9 949 9 9 ee s ees 123 4 5 6 43215 Sp 54 C 321 C INPUTS 12V DC SENSOR oe 12V DC RELAYS OUTPUT ROBERTS GORDON NEUTRALS BZC 300 E RELAYS L 98 LL NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 19 Typical EP 100 and EP 201 1ph Ex
56. onnection Diagram RoBERTS GorDON BZC 300 INSTALLATION MANUAL 1 7 HOW TO READ THE CONFIGURATION SHEET The tables shown on Page 4 Section 1 7 Figure 3 represent the assignments of relays and inputs that would result from the configuration of the panel for the example site layout shown on Page 2 Section 1 5 Figure 1 The outputs labeled RL1 through RL5 are the relay contacts shown on Page 3 Section 1 6 Figure 2 For the example shown the burners for Zone 1 will be connected to RL1 This is identified by the Zone number and the product description The column labeled EXTERNAL RELAY Y N indicates whether the current draw exceeds 4 4A If the cur rent draw is greater then a Y is indicated in this column see Page 13 Section 4 2 and Page 14 Section 4 3 for specific wiring instruction for exter TABLE OF OUPUTS OUTPUT ZONE NO PUMP NO PRODUCT EXTERNAL RELAY Y N SECTION NO D Zz A A Figure 3 Example Configuration Table Key to product definitions UNIT GORDONRAY BH Unitary Heater or UNIT CARIBE Unitary Heater or UNIT VANTAGE TF Unitary Heater or UNIT VANTAGE II or HE Unitary Heater HILO GORDONRAY DF Unitary Heater C FAN VANTAGE EV System CRV CORAYVAC Continuous System nal relays In the example each CORAYVAC zone requires one output for the burners and one for the pump The pump assigned to Zone 1 is conne
57. reen will now show ENTER LOWER TEMP 18 OFFSET LIMIT Unless instructed otherwise by the building owner leave at default 18 F or 5 C by pressing ENTER This is the number of degrees that the user will be able to decrease the set point using the DOWN ARROW in Normal Run Mode You will now be asked for the zone you want to alter If any of the zones are configured for HILO operation proceed to 6 3 10 Otherwise proceed to 6 3 8 below Press RUN to return you to the menu option Return to Normal Run Mode by pressing RUN If any mistakes were made during the programming sequence see Page 30 Section 6 1 for corrective action The following settings are optional the operating time and temperatures may be input if known GORDONRAY DF ONLY If you are at the Normal Run Mode repeat steps 6 3 1 to 6 3 7 until the entry of a zone number is requested Enter the zone number of the GORDONRAY DF The screen will now show ENTER THE HI LO DIFFERENCE 04 Unless instructed otherwise by the building owner type 04 and press ENTER Press Enter until the display requests the entry of switching times Press RUN to return you to the menu option Return to Normal Run Mode by pressing RUN If any mistakes were made during the programming sequence see Page 30 Section 6 1 for corrective action 31 RoBERTS GorDON BZC 300 INSTALLATION MANUAL 6 4 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 32 Z
58. rranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESENTATIVES No representative of Roberts Gordon other than an Executive Officer has authority to change or extend these provisions Changes or extensions shall be binding only if confirmed in writing by Roberts Gordon s duly authorized Executive Officer 43
59. s should be done as follows Burner lockout input wire for zone 1 goes into 12V DC Input 3 see Page 27 Figure 28 Burner lockout input wire for zone 2 goes into 12V DC Input 4 Burner lockout input wire for zone 3 goes into 12V DC Input 5 5 3 2 Details of Operation If burner lockout occurs the zone display of the controller will show LOCKOUT followed by the zone number on the status screen 27 GorRDON BZC 300 INSTALLATION MANUAL 5 4 BUILDING MANAGEMENT SYSTEMS REMOTE TIME ENABLE BMS Time Enable Contacts NC C NO 999 Input wire must be shielded cable Belden 8541 or equivalent D 9 1 2834 56 4499159 54 C 324 C jE INPUTS 12V DC pou SUN B 3 RELAYS RELAYS ROBERTS GORDON NEUTRALS BZC 300 e NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 29 Typical BMS Remote Time Enable External Wiring Diagram The BMS time enable diagram shown above is a facility available as standard on the ROBERTS GORDON BZC 300 Controller 5 4 4 Further Information The enable facility is only available on input 6 If it is required for your application it is pre configured by Roberts Gordon or a ROBERTS GORDON independent distributor prior to shipping The time enable will give a time on signal when the contacts are closed The time enable signal
60. s to the Burners 1 ph Individual supply for zone rated for total full load current See Page 7 Section 2 5 for details Zone 3 Zone 2 Zone 1 Sensor Sensor Sensor 12V DC 12V DC from relay 3 S 94 Sensor wire must be shielded The power supply for each Zone must be separate from the controller supply Zone 3Zone 2 Zone 1 Burner 2 All burners must be connected to Ground Not shown Burner 1 Line and Low voltage cable Belden 8451 or equivalent We separator plate 432158 devson INFOS 12V DC OUTPUT 1234 5 6 Pentre ROBERTS GORDON EvTRALS BZC 300 54 C RELAYS eee 321 RELAYS NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 15 Alternate Unitary External Wiring Diagram 12V DC switching 4 3 1 4 3 2 Description of external wiring diagram The external wiring diagram above shows the con nections for three zones of unitary burners via a load relay with a 12V DC coil Use the diagram in conjunction with the configuration sheet to identify which relays are to be used for unitary heaters Description of heaters ROBERTS GORDON Unitary
61. stallation of control systems for heating equipment Use Page 6 Section 1 9 of the original manual sup plied with this controller to identify the configura tion 7 1 DISPLAY PROBLEMS Does the display flash or show illegible text SECTION 7 TROUBLESHOOTING If this is not available use Page 34 Section 6 5 to view the configuration on the screen The troubleshooting section of this manual is divid ed into sections to make fault identification and rec tification easy to complete Yes Is the display blank fees Supply Yes ler Is it Check the mains fuse Y Is it OK See Page 38 Yes fuse Is it OK See Page Yes Figure 35 ITEM 1 j Check the ribbon cable is securely located at both ends Check the low voltage E 38 Figure 35 ITEM 5 J No a power supply Replace fuse with Replace fuse with Open the cover of the controller es Check the ribbon cable Is it Yes securely located at both ny Is the display flashing ai displaying illegible No Re fit See Page 38 Figure 35 ITEM 11 No Troubleshoot ends FIGURE 31 Display Troubleshooting Diagram 7 2 SENSOR PROBLEMS Does appear in place of current temperature e Check the chips Are they all securely seated Contact your
62. ternal Wiring Diagram 12V DC switching 4 7 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system The power to the pump is supplied separately and switched by the controller via a load relay with a 12V DC coil Refer to Page 10 Section 3 3 2 for pump alternatives For a VANTAGE EV system the pressure switch located at the pump is not required See Page 16 Section 4 5 for detailed sequence of operation SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 8 EP 301 1PH PUMP CONNECTION 120V AC COIL EP 301 Vacuum Pump Never directly connect the controller relay terminals to the Contactor pump motor P N 10050006 rated for the EP 301 pump motor Zone 1 e Burner 4 All burners must be connected to Ground not shown The power supply for each pump must be separate from the controller supply Burner 3 120 e en 1 Ph Burner 2 60Hz for pump rated for Sensor wire and in wire total full load current See Page 7 Section 2 3 Burner 1 cable Belden 8451 or equivalent dd for details Individual supply Line and Pressure switch Pr Low voltage separator located at vacuum plate Ground pump j L 1 LE 9 321 C JE RELAYS 43218S SENSOR INPUTS 12V DC OUTPU
63. the pressure switches to reset before re establishing or a lockout condition occurs or the heating is turned off by satisfying temperature set point After the heating is turned off by all zones reach ing the set point the pump will continue operation for a 2 minute post purge cycle SECTION 4 TYPICAL EXTERNAL DIAGRAMS 4 6 CORAYVAC SYSTEMS ARRANGED IN MULTIPLE ZONES EP100 or EP201 pump connection detail for pump alternatives refer to Page 10 Section 3 3 2 L Vacuum Pump ee Never directly connect the All burners must be connected controller relay terminals to to Ground Not shown 1 20V the pump motor 1 Ph Zone 3 Zone 2 Zone 1 ae ee 94 Burner 4 The power supply for Load Relay each pump must be separate from the controller Individual supply Neutral 120V Live 120V supply for pump rated for from relay 5 Zone 1 Zones Burner 3 total full load current 2 amp 3 SeePage 7 Section 2 3 for details Pump 1 Pump 2 gt Burner 2 Sensor wire and input E wire must be shielded cable Belden Line and 8451 or equivalent Low voltage separator Pressure switches plate Bumer located at Zone 3 Zone 2 Zone 1 vacuum pumps Sensor Sensor Sensor Pump 1 Pump2 Pressure Pressure FS switch 1 switch2 Ground
64. tion for a single zone CORAYVAC system EP 100 EP 201 or EP 301 1ph pumps with an outside Refer to Page 10 Section 3 3 2 for pump alterna air blower The power to the pump is supplied sep tives arately and switched by the controller via a load Refer to Page 7 Section 2 3 for correct overload relay for EP 100 or EP 201 or contactor for EP rating 301 with a 12V DC coil For other pumps with an outside air blower use the DC output from the panel to switch both the load relay at the blower and the contactor for the pump 24 SECTION 5 ALARM SIGNAL CONDITION MONITORING P SECTION 5 ALARM SIGNAL CONDITION MONITORING 5 1 Alarm signal condition monitoring capabilities are available as inputs to the controller The number of signals available is limited to the 6 inputs available Input 6 is reserved for remote time enable and input 5 is optionally available for fire safety over ride CORAYVAC pump pressure switches reserve the use of an input 3PH PUMP TRIP INDICATION FOR CORAYVAC AND VANTAGE EV SYSTEMS Vacuum Pump IEC contactor and overload rated for the pump motor IW The power supply for each pump must be separate from the controller supply 230V 3Ph 60 Sensor wire and input wire Individual supply must be for pump rated for shielded cable Belden 8451 or equivalent Zone 1 Sensor 9 ls See Page 7 Section for details Line and Low voltage separa
65. tor IEC contactor and Zone 1 overload rated for the pump motor 99 Burner 4 All burners must be connected to Ground not shown The power supply for each pump must be separate from the controller supply Burner 3 Burner 2 Sensor wire and input wire 230V must be shielded 3Ph total full load current Burner 1 cable Belden See Page 7 Section 2 3 8451 or equivalent 60Hz for details ile Pressure switch rapa m S Line and located at vacuum Low voltage G round pump separator plate 9 e 494 49 9 99 9 9 ee 5494949 sadad E e 8 123 4 5 6 4321S 54 C 321 12V DC OUTPUT ROBERTS GORDON NEUTRALS BZC 300 ee LL RELAYS INPUTS 12V DC SENSOR INPUTS RELAYS NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 22 Typical 3ph Pump Starter External Wiring Diagram 4 10 1 Description of external wiring diagram The external wiring diagram above shows the con nection for a single zone CORAYVAC system The power to the pump is supplied separately and switched by the controller via a contactor with a 120V AC coil Refer to Page 10 Section 3 3 2 for pump alternatives For a VANTAGE EV system the pressure switch located at the pump
66. tor plate Pressure switch located at vacuum total full load current Never directly connect the controller relay terminals to the pump motor 2 3 Zone 1 All burners must be connected to Ground not shown ee Burner 4 Burner 3 Burner 2 Burner 1 Ground E e e gt N Bn 43218S 4 SENSOR e 12V DC OUTPUT 54 C RELAYS ROBERTS GORDON BZC 300 T 321 RELAYS 9 e 120 V 1 ph 60 Hz ee NOTE TYPICAL LAYOUT DRAWINGS TO BE USED IN CONJUNCTION WITH FACTORY CONFIGURATION SETTINGS PAGE 6 SECTION 1 9 FIGURE 26 Typical 3ph Pump Trip Indication External Wiring Diagram 5 1 1 NOTE Details of Operation The pump trip wiring diagram shown above refers to the CORAYVAC and VANTAGE EV system configurations An overload with normally open contacts is required A typical IEC contactor and overload is shown on Page 25 Section 5 1 Figure 26 The pressure switch is not required for VANTAGE EV systems If pump trip occurs the zone display on the con troller will show HEATER LOCKOUT followed by the zone number Indication will show that the over load has tripped 5 1 2 Further Information The overload must be manually reset Check and adjust the overload if required refer to Page
67. ty shut off is activated the con troller changes the set point temperature to 00 for every zone 29 RoBERTS GorDON BZC 300 INSTALLATION MANUAL P SECTION 6 ENGINEER S SET UP 6 1 6 1 1 6 1 3 6 1 4 6 2 6 2 1 30 IMPORTANT BEFORE PROGRAMMING READ THIS SECTION Check that the controller has been configured for the specific installation See Page 34 Section 6 5 and compare the settings to the configuration sheet on Page 6 Section 1 9 If the controller has not been configured or has been configured incorrectly do not program the controller Configuring the con troller will erase all the previously input settings and restore the defaults If the configuration is not correct contact your ROBERTS GORDON independent distributor or Roberts Gordon If any step is unclear please contact your ROBERTS GORDON independent distributor or Roberts Gordon at 716 852 4400 or 800 828 7450 in the U S 905 945 5403 in Canada or at WWW rg inc com The temperature units of measure can be selected as Fahrenheit or Centigrade The setting for tem perature units of measure will be found in the con figuration settings See Page 34 Section 6 5 to view the settings The display of temperature on the screens in the following programming instructions is in Fahrenheit The following section describes the procedure for setting up the controller For operating instructions please consult the ROBERTS GORDON BZC 300
68. ver directly connect the controller relay terminals 1 20V to the pump motor All burners must be connected to Ground Not shown Zone 3 Zone 2 Zone 1 1Ph UNIT CRV CRV 60Hz Yi Burner 4 The power supply for 1 each pump must be 9 0 separate from the controller Individual supply Neutral 120V Live 120V supply for pump rated for from relay 5 Zone 1 Zone 2 ee jee Burner 3 total full load current See Page 7 Section 2 3 for details Pump 1 Pump 2 Sensor wire 99 144 64 Burner 2 must be shielded ii m cable Belden Line and 8451 or equivalent Low voltage separator Pressure switches plate 64 jes Burner 1 located at vacuum pumps Zone 3 Zone 2 Zone 1 d Kl Sensor Sensor Sensor Pump 1 Pump 2 L4 Pressure Pressure switch 1 switch 2 p p HA Ground jh A T ie qe alee iT e pli Lo T N 9 9 9 9 9 b 949 9 9 ee 98 54 ees e ee eee 123 465 6 492195 54 C 321 C E LL 120V INPUTS 12V DC SENSOR INPUTS 12V DC RELAYS RELAYS 46 1Ph OUTPUT RS485 NEUTRALS 60Hz ROBERTS GORDON TE EL BZC 300 Input wire must be shielded cable Belden 8451 or equivalent
69. ver panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover Locate the fuse on Page 38 Figure 35 ITEM 1 and remove the fuse with a fuse pulling tool Replace with a new fuse rated at 500mA Anti Surge Reconnect the ribbon cable to the main board and replace the cover of the controller by replacing the four securing screws LED Relay Status There are 5 status LEDs on the board one for each relay When the relays are energized the appropri ate LED will be lit Voltage Selector Switch The voltage selector switch has 2 settings 115 for 120V supply 230 for 230V 1ph supply This switch must be set to 115 for use in North America Transformer The transformer on the board cannot be replaced 100000203 Low Voltage Fuse Board 315mA This low voltage fuse protects the controller circuit board If the low voltage fuse needs replacing the follow ing steps must be taken Turn off the power to the controller Remove the clips and screws from the cover panel and remove the cover of the controller Disconnect the ribbon cable from the main board only leaving the ribbon attached to the cover 8 2 6 8 2 7 SECTION 8 REPLACEMENT PARTS Locate the fuse on Page 38 Figure 35 ITEM 5 and remove the fuse with a fuse pulling tool Replace with a new fuse rated at 500mA quick blow Reconnect the ribbon cable to the main board
70. vice use of replacement parts or acces sories that are not specified by Roberts Gordon Improper installation or any relocation of the ROBERTS GORDON BZC 300 Controller after initial installation Incorrect supply accident fire flood acts of God or other casualty Use of the ROBERTS GORDON BZC 300 Controller for other than its intended purpose Use of the ROBERTS GORDON BZC 300 Controller in a corrosive atmosphere or any atmosphere containing contaminants Shipping Claim must be filed with carrier WARRANTY IS VOID IF The ROBERTS GORDON BZC 300 Controller is not installed by a electrician qualified in the installation of con trol systems for heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ROBERTS GORDON BZC 300 Controller is trans ferred This warranty is nontransferable Roberts Gordon is not permitted to inspect the damaged ROBERTS GORDON BZC 300 Controller and or compo nent parts READ YOUR INSTALLATION MANUAL If you have questions about your ROBERTS GORDON BZC 300 Controller contact your installing professional Should you need replacement parts or have additional questions call or write Roberts Gordon U S A 1250 William Street P O Box 44 Buffalo New York 14240 0044 Telephone 716 852 4400 Fax 716 852 0854 Canada 241 South Service
71. y wiring OK O Refer to the CORAYVAC Installation Operation and Service Manual or contact your ROBERTS GORDON9 Independent Distributor Contact ROBERTS GORDONG at www rg inc com Troubleshoot ends FIGURE 34 CORAYVAC Troubleshooting Diagram 7 6 SCREEN DISPLAYS In Normal Run Mode the following options are available without the entry of a security code INFORMATION SCREENS Pressing the SCROLL key will enable you to scroll through the zones one by one The following screens will be displayed STATUS Day xis WED 12 10 10 14 15 30 NND Time H M S On Off period for each zone Day or Night 99 Service Manual or contact your No ROBERTS GORDON Independent Distributor switch OK See Page 38 Figure 35 ITEM 2 Refer to the CORAYVAC Contact ROBERTS GORDONG at www rg inc com and Rectify ZONE INFORMATION Required Zone Temp zm HEAT ON Heating Actual ON OFF Zone Temp To manually bring on a zone highlight the zone as above and use the UP 3 and DOWN 7 arrow keys to adjust the set point Zone Title 37 RoBERTS GoRDON BZC 300 INSTALLATION MANUAL P SECTION 8 REPLACEMENT PARTS e e e ee 123 45 6 4321S5S 54 C 321 C L E INPUTS 12V DC SENSOR INPUTS 4 d UT RELAYS RELAYS NEUTRALS O a

9-06-BZC 300 Controller Manual

Contents

Download Pdf Manuals

Related Search

Related Contents